GENERAL COMPANY FOR CHEMICAL
INDUSTRIES
A PANORAMIC VIEW OF GCCI
INTRODUCTION TO GCCI
The construction of the GCCI at Abu Kammash is one of the largest
industrial projects carried out in the LIBYAN Jamahiriya . The vital
factors of this project to Libya are :
The Chemical Complex utilizes Libyan natural resources of brine,
oil products and manpower .
The main products are Poly Vinyl Chloride ( PVC ) , Caustic Soda
and Chlorine which is used as raw materials for other industries .
The availability of these products are at realistic prices and hence
aggravates the industrial growth of the country as a whole .
Another important product is the Table Salt . The Chemical
Complex provides the total demand of salt for Libya.
These high quality and competitively priced products are also
exported to international markets.
THE ROLE AND AIM OF GCCI
The Chemical Complex has led to the creation of
new jobs and the need to provide training facilities.
It has provided skilled workers for other industrial
projects .
The complex is a part of the industrial future of
the Jamahiriya and its role is to be recognized as
an industrialized nation.
Another goal is to supplement the future , the
income from the oil industry and eliminate the
need to import key chemicals and plastic
materials.
HEAD OFFICE OF GCCI
GENERAL INFORMATION OF GCCI
The project is based on the utilization of salt lake
(brine) which is located in the north west of Libya,
and oil products (Ethylene) which is imported from
Ras Lanuf.
Commissioning of the Complex started in April
1980 and it operates on a three shift basis
employing a total of 1,500 personnel .
Accommodation for GCCI personnel built at Abu
Kammash village (2) consisting of 500 houses and
other 112 new houses at Abu Kammash village (1)
including all utilities and facilities.
The following are the materials produced:
Poly Vinyl Chloride (PVC).
Caustic Soda.
Table Salt.
Chlorine.
Hydrochloric Acid.
Sodium Hypochlorite.
The design of the Complex has been carried out
with every effort to minimize the effect of land , sea
and air pollution . All waste streams are treated for
removal of pollutants and are monitored before
discharge to the environment.
BRINE WINNING & PURIFICATION
In the summer months brine is
pumped from wells by
submerged pumps (38 wells in
three lines) and in the winter
months by pumping from the
surface of the Sebkha.
The brine is then transferred
through an 18 Km pipe line to the
Complex and stored in two
basins .
After settling the brine it is
filtered and transferred to the salt
plant .
THE SALT PRODUCTION
SALT PLANT EVAPORATORS
Salt production is from the brine in a multi stage
vacuum evaporation crystallization.
The salt is separated from the slurry from the
evaporators by centrifuge and part is transferred as
wet salt to the electrolysis plant.
The other part of the salt is dried , an antic king
agent and potassium iodide being added before it is
packed into 1 Kg bag and 50 kg bags for sale.
The water obtained from evaporation of the brine is
used within the Complex as a source of soft water .
AUTOMATED SALT PACKING
PACKING OF TABLE SALT
THE ELECTROLYSIS
ELECTROLYSIS CELL ROOM
The wet salt from the salt plant is converted into brine,
purified by chemical treatment and then electrolyzed in
mercury cells to produce chlorine, hydrogen and sodium
hydroxide as 50% solution.
The chlorine is dried and compressed and the major part
utilized for the production of vinyl chloride monomer . The
remainder is liquefied for sale in cylinders and drums.
The 50% caustic soda solution are concentrated to produce
a fused product from which 98% concentration are packed
into plastic sacks .
Sodium Hypochlorite is produced as a solution by the
reaction of chlorine with sodium hydroxide solution .
The 50% caustic soda solution is being sold as a final product
which is transported by sea, road or tankers.
Chlorine Cylinders
Loading of bleaching lye
and Hydrochloric acid
THE VCM PRODUCTION UNIT
Ethylene is supplied to the complex by ship in liquid ethylene
carriers . The ethylene at present delivered from Ras Lanuf
complex , Libya . The ethylene is pumped from the sea bridge to
the storage tanks . The ethylene is evaporated and supplied to the
chloride monomer plant .
Ethylene dichloride is produced by the reaction of chlorine with
ethylene in the direct chlorination unit the ethylene dichloride is
purified by distillation and then feed to the cracking unit where it is
spilt into vinyl chloride monomer (VCM) and hydrogen chloride .
The hydrogen chloride is recycled to the ox hydro chlorination
unit where it reacts with more ethylene and oxygen , from the air ,
to form further ethylene dichloride which is purified and cracked in
the same way and unconverted EDC .
The vinyl chloride is then separated by distillation , dried and
stored in spheres . The chlorinated by-products are burnt in an
incineration unit to produce 27% hydrochloric acid .
VCM storage spheres
Ethylene storage tanks
THE PVC PRODUCTION UNIT
Poly vinyl chloride (PVC) resin is a white powder which is
produced in four grades , two of which are types S7054 and S6554.
These are soft resins intended for a wide range of uses like cable
insulation, footwears and general household goods.
The third grade S6858 is intended for pipe manufacturing and
other rigid extrusions. The fourth grade S5858 for bottle
manufacturing.
Polymerization takes place and solid PVC suspension from the
reactors is processed to remove the untreated vinyl chloride which
is recycled , and the solid separated in a centrifuge and dried.
The dry resin is stored in silos and then packed into 25 Kg paper
sacks , palletized and shrink wrapped or transported by road
tankers.
PVC CONTROL ROOM
PVC STORAGE SILOS
AUXILIARY UNITS
The Complex is provided with auxiliary units to supply the
production plants with essential services.
Sea Water intake: The sea water pumping station, located
on the sea bridge, provides sea water for cooling
purposes and feeds to the seawater desalination unit.
Sea Water Desalination: The sea unit provides 220
tons/hour of fresh water for use in the Complex.
Water Hardening Unit: This provides drinking water for the
Complex and Camps and fire fighting water for the
Complex.
Steam Generation Unit: Steam is generated in oil fired
boilers. A dematerialization unit is provided in the boiler
house for the supply of the boiler feed water and
dematerialized water for the production units .
Compressed Air Unit. A Compressed air unit is provided to
supply compressed air to the production units for use in the
processes and for instrumentation.
Nitrogen Generation Unit. Nitrogen is used in the production
units , It is produced by burning oil or hydrogen.
Electrical Supply. Electricity is supplied to the Complex at
30 Kv and then stepped down to 10.8 Kv and / or 0.4 Kv .
Emergency generating sets are provided to ensure a safe
shut down of the Complex in the event of a power failure.
ANNUAL PRODUCTION OF PLANTS
Annual production
in Tons
Consumption in
Complex
Tons
For Sale in
Tons
1. Table Salt
(Sodium Chloride)
120.000
80.000
40.000
2. Caustic Soda (100%)
(Sodium Hydroxide)
51.600
2.600
49.000
3. Vinyl Chloride Monomer
(VCM)
62.500
62.500
4. Poly Vinyl Chloride
60.000
60.000
5. Chlorine
45.700
40.700
5.000
6. Hydrochloric Acid (HCl) (30%)
9.000
1.000
8.000
7. Sodium Hypochlorite
8.900
8,900
Name of product
COMPARISON FOR ACTUAL PRODUCTION OF POLY VINYL CHLORIDE
FROM THE YEAR 1993 - 2003
ACTUAL PRODUCTION
(QTY BY TONS & AMOUNT BY LD)
QUANTITY
YEAR
AMOUNT
15699903
41223
1993
20728047
43090
1994
26486838
49430
1995
16691821
41015
1996
29210977
42852
1997
32141430
56816
1998
48336
1999
52336
2000
41468
2001
26715762
36865
2002
39801571
50676
2003
28145888
35438890
17782231
ACTUAL PRODUCTION OF PVC FROM THE YEAR 1993 - 2003
60000
50000
40000
30000
20000
10000
0
2003
2002
2001
2000
1999
1998
1997
1996
1995
1994
1993
EVALUATION OF PVC PRODUCTION FOR THE YEAR 1993 - 2003
45000000
40000000
35000000
30000000
25000000
20000000
15000000
10000000
5000000
0
2003
2002
2001
2000
1999
1998
1997
1996
1995
1994
1993
COMPARISON OF ACTUAL PRODUCTION OF CAUSTIC
SODA FOR THE YEAR 1993 - 2003
YEAR
ACTUAL PRODUCTION
QUANTITY
AMOUNT
1993
36866
11019623
1994
33630
13305968
1995
36404
17935816
1996
30789
13299464
1997
32840
14134388
1998
42733
16079447
1999
36694
13601191
2000
38649
9982008
2001
33364
11952813
2002
28657
6205980
2003
36095
7192297
ACTUAL PRODUCTION OF CAUSTIC SODA FOR THE YEAR 1993-2003
45000
40000
35000
30000
25000
20000
15000
10000
5000
0
2003
2002
2001
2000
1999
1998
1997
1996
1995
1994
1993
EVALUATION OF PRODUCTION OF CAUSTIC SODA FOR THE YEAR 1993-2003
20000000
18000000
16000000
14000000
12000000
10000000
8000000
6000000
4000000
2000000
THE PRESTEGIOUS AWARDS OF
GCCI
GCCI IS REWARDED WITH
Quality of the products which was
recognised in several occasions with
international awards and certificates for
quality.
Established and maintains a quality
management system relevant for
manufacturing of several chemical
products mentioned & shown in this
brochure.
2-1 Quality Policy (ISO 9001: 2000 / 5.3)
General Company For Chemical Industries Quality
Policy Is:
To provide company products (Chemical Products) and related services with quality that meets marketing
requirements, customer satisfaction and comply with technical specification at reasonable price and lowest
cost.
Continual improvement in the quality of products by using modern technology in chemical industries and
effectiveness of the quality management system.
Continuous training and performance improvement for all employees to achieve optimum efficiency of
processes and activities performance.
Working as teamwork using the scientific methods in all working fields to increase productivity and reduce
waste of material and time .
Companys quality objectives are established by the peoples committee and the departmental objectives
are established by both departmental general managers and managers and reviewed through management
reviews meetings.
This policy has been declared at all levels in a manner which ensures the full This policy is reviewed on
annually basis during meetings of management reviews for continuous suitability.
Approved by:
GCCI performance has been
consolidated by ISO 9001/2000 certification
obtained in 15/1/2002 which was an
illustration of its wellness to continue the
progress and improvement of the quality
system.
(
)
Eng. Nouri Ramadan GerSecretary of Peoples Committee
& Management Representative
